Abstract: Techniques for three dimensional printing of reinforced wall structures using extruded solidifiable material includes printing a first wythe that comprises a first plurality of stacked elongated beads of extruded material, printing a second wythe that comprises a second plurality of stacked elongated beads of extruded material, and building a porous layer disposed between the first wythe and the second wythe. In some examples, embedded reinforcement using mesh, wire, rebar, or other horizontally, diagonally, or vertically-emplaced members may also be performed, where the embedded reinforcement is placed between wythes or within (e.g., disposed within a bead of material, embedded reinforcement is placed) individual beads of a wythe.

Abstract: Techniques for and examples of a partition wall structure of a building are described, including a first shell formed as a first wythe including a first group of stacked elongated beads of extruded building material, a second shell spaced apart from the first shell and formed as a second wythe that has a second group of stacked elongated beads of extruded building material, and at least one structural support having a first portion embedded in the first wythe, and a second portion embedded in the second wythe.

Abstract: Techniques for additive construction of structures and production of additive construction materials are described, including a 3D printing assembly including a container configured to store a material, a mixer configured to mix the material to provide an extrudable mix including cementitious material, and a dispenser configured to receive the flowable mix from the mixer and to provide the flowable mix under one or more controlled parameters to form a structure, and a controller configured to receive a value associated with a material property parameter of the material, to generate a mixture by inputting the value into a machine learning algorithm, the mixture being generated using, by the controller, another value associated with a control parameter configured to control operation of the 3D printing assembly, and using the 3D printing assembly to print a structure using the mixture.

Abstract: Techniques for and examples of wall structures of extrudable building material includes forming, with a three-dimensional (3D) printing system, a first portion of a first shell with a first wythe that comprises a first group of stacked elongated beads of an extrudable building material, forming with the 3D printing system a first portion of a second shell with a second wythe that comprises a second group of stacked elongated beads of the extrudable building material and is spaced apart from the first wythe, and installing at least one structural support that comprises a first portion positioned in the first wythe and a second portion positioned in the second wythe.

Abstract: Techniques of and examples for wall structures of extrudable building material include forming, with a three-dimensional (3D) printing system, a first portion of a first shell that includes a first plurality of stacked elongated beads of extruded building material that forms a first wythe, the first shell forming a first surface of the load-bearing wall structure, forming, with the 3D printing system, a first portion of a second shell spaced apart from the first shell, the second shell having a second plurality of stacked elongated beads of extruded building material that forms at least two second wythes, the second shell forming a second surface of the load-bearing wall structure, and installing at least one structural support that has a first portion positioned in the first shell and a second portion positioned in the second shell.

Abstract: A wall structure and a method for forming a wall structure is provided using three-dimensional printing of extruded building material applied to a surface of a building structure. According to one embodiment, the wall structure includes a pair of outer wythes spaced from an inner wythe. The outer wythes can include a core extending between the pair of outer wythes and toward the inner wythe. A protrusion can also extend toward the inner wythe a spaced distance from the inner wythe or entirely toward and adjoining the inner wythe. The core is configured with an inwardly facing spaced opposed surfaces of the outer wythes surrounding a vertically extending rebar, with grout surrounding that rebar. Horizontally extending support pins can be spaced parallel from each other and extend from the protrusions and into the inner wythe.

Abstract: Systems and methods for preparing a three-dimensional printing material derived from aluminosilicate material are provided. The method includes the steps of heating an amount of aluminosilicate powder to a temperature between approximately 1,100° C. and approximately 1,750° C. to form a molten aluminosilicate material; maintaining the molten aluminosilicate material at a temperature between approximately 1,100° C. and approximately 1,750° C. between about one minute and approximately 45 minutes; extruding molten aluminosilicate material through a nozzle to form an elongated bead of molten aluminosilicate material; and cooling the molten aluminosilicate material to form a hardened aluminosilicate material. Once hardened, the aluminosilicate material includes between about 50% and 90% feldspar and demonstrates a strength of between about 5,000 psi and 30,000 psi.

Abstract: Techniques for and examples of wall structures formed of extrudable building material (i.e., extrudable material) include a first shell having a first group of stacked elongated beads of extruded material that forms a first wythe, the first shell forming a first surface of the load-bearing wall structure, a second shell spaced apart from the first shell, the second shell having a second group of stacked elongated beads of extruded material that forms at least two second wythes, the at least two second wythes forming a second surface of the load-bearing wall structure, and at least one structural support that has a first portion embedded in the first shell and a second portion embedded in the second shell.

Abstract: A system and method is provided to construct a structure using three dimensional printing of extrudable building material to a wall surface of a structure. According to one embodiment, a printing assembly is moveably disposed above the surface, and extrudable building material is applied from a nozzle onto the surface. One or more profilometers measure at periodic intervals along a geometric cross-section of a bead of extrudable building material. One or more controllers compare the measured cross-section to a predetermined, target cross section and one or more controllers periodically change, for example, the rate of application and/or the viscosity of the extrudable building material applied along the longitudinal axis. The nozzle direction can change, and the profilometers can be rotated about the nozzle along different longitudinal axes, or directions, depending on the wall locations being formed.

Abstract: Embodiments disclosed herein relate to methods of constructing a structure and related non-transitory computer readable medium. In an embodiment, the method includes (a) defining a vertical first slice and a second vertical slice of the structure. A lateral cross-section of the structure within the first vertical slice is different than the lateral cross-section of the structure for the second vertical slice. In addition, the method includes (b) depositing a plurality of first vertically stacked layers of an extrudable building material with a printing assembly to form the first vertical slice. Further, the method includes depositing a plurality of second vertically stacked layers of the extrudable building material atop the first vertical slice with the printing assembly to form the second vertical slice.

Abstract: Material delivery systems as well as systems and methods relating thereto are disclosed. In an embodiment, the material delivery system includes a tank to hold water therein. In addition, the material delivery system includes a hopper to hold dry ingredients of the extrudable building material therein. Further, the material delivery system includes a mixing unit to receive water from the tank and dry ingredients from the hopper. The mixing unit includes an agitator to mix the water and the dry ingredients together to form the extrudable building material. Still further, the material delivery system includes a controller coupled to the agitator that is to: measure a load imparted to the agitator by the extrudable building material, add additional water to the mixing unit when the load is above a first threshold, and add additional dry ingredients to the mixing unit when the load is below a second threshold.

Abstract: A three dimensional printer can include: at least one beam configured to support a shuttle for a printhead of the three dimensional printer; and at least one tower configured to support the at least one beam; where the at least one beam and the at least one tower include a frame having a structural design produced from an iterative design process that employs a generative design algorithm to optimize a shape and/or topology of the frame, thereby reducing a ratio of a total mass over a total print build volume of the three dimensional printer.

Abstract: An apparatus, system and method are provided for launching, deploying and moving mobility platforms used to produce a three-dimensional product using additive printing. The product, or object, is made by collecting materials in-situ at an off-Earth celestial body. A sintering apparatus, such as a laser, is used to consolidate the planetary regrowth into a solid object. The apparatus can receive power, and can apply heat to assist in the consolidation process. The apparatus is moveable to the build site, and includes a print head having a collector for receiving collected materials, a conditioner for sintering and heating the collected materials, and an extruder, specifically a slip form opening in which the materials can be dispersed over the surface of the extraterrestrial body where the powder form of the conditioned materials are sintered, fused, or consolidated into a hard solid bead of material.

Abstract: Mix formulation for 3D printing of structures is described, including a composition of an aluminosilicate source and an activator. Also described is a method that includes combining a composition having an aluminosilicate source and an activator with aggregate to yield a mixture, extruding a first quantity of the mixture through a nozzle to form a first layer of the mixture, extruding a second quantity of the mixture through the nozzle to form a second layer of the mixture substantially on the first layer, and curing the first layer and the second layer to yield a structure printed using a 3D printer.

Abstract: Embodiments disclosed herein relate to methods of constructing a structure and related non-transitory computer readable medium. In an embodiment, the method includes (a) defining a vertical first slice and a second vertical slice of the structure. A lateral cross-section of the structure within the first vertical slice is different than the lateral cross-section of the structure for the second vertical slice. In addition, the method includes (b) depositing a plurality of first vertically stacked layers of an extrudable building material with a printing assembly to form the first vertical slice. Further, the method includes depositing a plurality of second vertically stacked layers of the extrudable building material atop the first vertical slice with the printing assembly to form the second vertical slice.

Abstract: A system and method is provided to construct a structure using three dimensional printing of extrudable building material to a wall surface of a structure. According to one embodiment, a printing assembly is moveably disposed above the surface, and extrudable building material is applied from a nozzle onto the surface. One or more profilometers measure at periodic intervals along a geometric cross-section of a bead of extrudable building material. One or more controllers compare the measured cross-section to a predetermined, target cross section and one or more controllers periodically change, for example, the rate of application and/or the viscosity of the extrudable building material applied along the longitudinal axis. The nozzle direction can change, and the profilometers can be rotated about the nozzle along different longitudinal axes, or directions, depending on the wall locations being formed.

Abstract: A wall structure and a method for forming a wall structure is provided using three-dimensional printing of extruded building material applied to a surface of a building structure. According to one embodiment, the wall structure includes a pair of outer wythes spaced from an inner wythe. The outer wythes can include a core extending between the pair of outer wythes and toward the inner wythe. A protrusion can also extend toward the inner wythe a spaced distance from the inner wythe or entirely toward and adjoining the inner wythe. The core is configured with an inwardly facing spaced opposed surfaces of the outer wythes surrounding a vertically extending rebar, with grout surrounding that rebar. Horizontally extending support pins can be spaced parallel from each other and extend from the protrusions and into the inner wythe.

Abstract: Construction systems for constructing a structure on a foundation and methods relating thereto are disclosed. In an embodiment, the construction system includes a rail assembly configured to be mounted to the foundation. In addition, the construction system includes a gantry movably disposed on the rail assembly configured to translate along a first axis relative to the rail assembly. Further, the construction system includes a printing assembly movably disposed on the gantry and configured to translate along a second axis relative to the gantry. The second axis is orthogonal to the first axis. The printing assembly is configured to deposit vertically stacked layers of an extrudable building material on the foundation to construct the structure. The gantry has a width along the second axis that is configured to be adjusted relative to the foundation.